Treatment of cellulosic textile materials with a sulfonamide-urea-formaldehyde reaction product to impart crease resistance thereto

ABSTRACT

Cellulosic textiles are creaseproofed by treatment with a composition comprising the product of the interaction of 1 mole methanesulfonamide, from about 0.2 mole to about 2 moles of urea or carbamylurea, and from about 3 to about 10 moles formaldehyde, said product having a free formaldehyde content of from about 10 percent to 50 percent.

United States Patent [72] Inventor Ashley Dwight Nevers King of Prussia, Pa.

[21 1 Appl. No. 53,697

[22] Filed July 9, 1970 [45] Patented Dec. 28, 1971 [73] Assignee Pennwalt Corporation Philadelphia, Pa.

Original application on. 31, 1966, Ser. No. 590,558, now Patent N0. 3,536,648. Dlvided and this application July 9, 1970, Ser. No. 53,697

[54] TREATMENT OF CELLULOSIC TEXTILE MATERIALS WITH A SULFONAMIDE-UREA- FORMALDEHYDE REACTION PRODUCT T0 IMPART CREASE RESISTANCE THERETO 4 Claims, No Drawings [52] US. Cl 8/116-3, 8/115.6, 38/144, 2/243, 8/116.2

Primary Examiner-George F. Lesmes Assistant Examiner-J. Cannon Attorneys-Stanley Litz and Carl A. Hechmer, Jr.

ABSTRACT: Cellulosic textiles are creaseproofed by treatment with a composition comprising the product of the interaction of 1 mole methanesulfonamide, from about 0.2 mole to about 2 moles of urea or carbamylurea, and from about 3 to about 10 moles formaldehyde, said product having a free formaldehyde content of from about 10 percent to 50 percent.

TREATMENT OF CELLULOSIC TEXTILE MATERIALS WITH A SULFONAMlDE-UREA-FORMALDEHYDE REACTION PRODUCT TO IMPART CREASE RESISTANCE THERETO This application is a divisional of application Ser. No. 590,558, filed Oct. 31, 1966, now U.S. Pat. No. 3,536,648.

This invention relates to a novel composition useful as a finishing agent for cellulosic textiles and to the method of treating cellulosic textile materials with said composition to impart crease resistance and wrinkle recovery properties thereto, and to the crease-resistant textile produced thereby. More particularly, this invention is concerned with a creaseproofing agent for cellulosic textiles which comprises the product obtained by interacting methanesulfonamide, urea, and formaldehyde, said product further characterized by having a free formaldehyde content within the range of about it) percent to about 50 percent, based on the total weight of said interactants. This invention is also particularly concerned with the application of said product to a cellulosic fabric and the curing of the treated fabric with heat to impart wash-wear and durable-press characteristics thereto.

As used herein, the terms "cellulosic textile, cellulosic textile material," and cellulosic fabric" refer to fabrics, whether woven or nonwoven, containing at least about percent of cellulose fiber, prepared from cotton, mercerized cotton, rayon, linen, flax, cellulose acetate and like cellulosic materials. These cellulosic materials may be employed in fabrics as blends, i.e., in combination with other natural or synthetic noncellulosic materials, such as, for example, wool, nylon, acrylic fibers, polyester fibers and the like, and it is to be understood that these blends are subject to treatment according to this invention with good results.

In recent years there has been extensive experimentation and commercialization of methods for treating cellulosic fabrics with various creaseproofing substances and reaction products to impart so-ealled wash and wear" properties to said fabrics. Said wash and wear" properties include dimensional stability and crease or wrinkle resistance, wherein said resistance is retained by the fabric through repeated launderings. These finishing agents are generally compounds which contain at least two functional groups (such as a plurality of CH,OH groups) which react with and cause cross-linking between the molecular chains of the cellulose when the fabric is subjected to a catalyzed heat cure treatment.

The cellulosic fabrics which are treated in accordance with this invention have, in addition to excellent wash and wear" characteristics, a combination of other desirable properties. Firstly, there is a marked advantage noted in the processing of the fabrics. Despite the fact that there is free formaldehyde present in the reaction product embodied herein, there is .elative freedom from obnoxious odors during the treating and curing of the fabrics as hereinafter described, in comparison to a greater level of irritating fumes evolved in these operations using some of the finishing agents heretofore available. The cellulosic fabrics which are treated according to this invention have good color, which advantage is exemplified by the relative initial whiteness of the treated fabrics and their resistance to yellowing after numerous launderings. The cellulosic fabrics treated according to this invention also have high resistance to acid hydrolysis and minimal loss of tensile strength subsequent to chlorine bleaching and scorching. It is very significant that these good properties can be attained with a smaller amount of textile finishing agent than is normally used for wash and wear fabrics.

PREPARATION OF THE CREASEPROOFING PRODUCT The creaseproofing agent of this invention comprises the product obtained by the interaction of methanesulfonamide, urea, and formaldehyde in certain specific proportions. The preferred urea reactant is unsubstituted urea; however, in lieu thereof, carbamyl urea (biuret) or mixtures of urea and biuret in any proportions may be used as the urea component in the interaction. The formaldehyde reactant is generally used as the commercially available 37 percent aqueous solution Formalin"), although the 55 percent solution of formaldehyde in methanol (Methyl Formcel) or the polymeric form of the compound known as paraformaldehyde, which is also commercially available, can be employed with good results. An aqueous solution of formaldehyde, which is preferred, may or may not contain the conventional inhibitor additives.

The creaseproofing agent embodied therein is obtained by interacting 1 mole of methanesulfonamide, from about 0.2 mole to about 2 moles of the urea and from about 3 to about 10 moles of formaldehyde. The preferred range of formaldehyde is from about 4 to about 6 moles per mole of alkylsulfonamide. It is preferred to employ from about 0.5 to about 1.5 moles of urea per mole of methanesulfonamide and, in general, it is most preferred that this ratio be essentially equimolar because it has been found that fabrics treated with product so prepared have the best resistance to loss of strength caused by chlorine bleaching. The interaction of the three foregoing components to prepare the unique reaction product is most conveniently and desirably carried out in aqueous solution wherein the proportions of reactive ingredients and water are such that the final reaction product solution contains from about 30 percent to about 50 percent, based on the total weight of the solution, of product solids (i.e., total dissolved interactants). Other solvent systems for the reactants and the product can be used instead of water, for example, a lower alkanol, e.g., methanol, ethanol, isopropanol; dimethylsulfoxide, dioxane, aliphatic ethers, aliphatic glycols, glycol ethers and the like.

It is desirable to carry out the reaction in alkaline media, preferably at a pH in the range of about 8 to 9. The pH is conveniently adjusted by adding small amounts of aqueous alkaline material to the reaction mixture prior to interaction of the components and, usually, alkaline material is added incrementally during the reaction period to maintain the alkaline conditions. Suitable alkaline additives include sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate and the like.

The interaction of the methanesulfonamide, urea and formaldehyde to produce the product of this invention is favored by supplying heat to the reaction mixture, and therefore, the interaction is generally conducted for from about 2 to about 12 hours at temperatures within the range of about 50 C. to about l00 C., preferably about to I00 C. Although lower temperatures, e.g., as low as about 25 C., may be used, the reaction period then required is so extended that lower temperature interaction is not recommended. Moreover, the performance of the lower temperature interacted product as a creaseproofing agent will not be as effective as that of the product prepared at the higher temperatures.

The interaction of the three components is sustained until there is a specific level of free formaldehyde present. By free formaldehyde" is meant that formaldehyde which is not chemically bound to the other constituents of the reaction product. The percent of free formaldehyde in the aqueous reaction product is conveniently determined by the following procedure (however, other acceptable analytical methods may be used). A few drops of a 0.] percent solution of mixed indicator (l part methyl red and 5 parts bromcresol green) is added to a weighed 1 ml. or 2 ml. sample of the aqueous reaction product. The sample is neutralized by gradually adding 0.5N HCl or H 80, to the indicator end point. Then 20 ml. of 10 percent hydroxylamine hydrochloride solution is added and the mixture is allowed to stand for 15 minutes. It is then titrated to the mixed indicator end point with 0.5N NaOH solution (the color will change from orange-pink to nearly colorless). A blank titration with the NaOH is run separately on a 20 ml. sample of hydroxylamine hydrochloride solution. The free formaldehyde in the product is calculated as: Perot-lit trot ll tl Normality of Nntlll solu. (ml. titration sample ml. tit-ration l1l;i nk). Il(ltl Wt. sample tgnts.)\pt-ret-nt of interuetnnts in sampli- It has been found that to obtain good cellulosic fabric finishing the reaction product of this invention should contain from about 10 percent to about 50 percent, preferably from about 12 percent to about 40 percent, of free formaldehyde, based on the weight of total dksolved interactants in the treating solution. (Total dissolved interactants is defined as the total amount of methanesulfonamide, urea, and formaldehyde charged to prepare the product).

The interaction of the three component system may be car ried out using either one-step or two-step techniques. In the one-step technique the total charge of all three components is initially mixed together in solution and the mixture is heated and the reaction sustained until the free formaldehyde level is within the above-mentioned range.

In the two-step technique, of which there are two embodiments as hereinafter discussed, an initial interaction is conducted between, for example, 1 mole of methanesulfonamide, the urea, and about 2 moles of formaldehyde. This mixture is advantageously heated until the free formaldehyde content is from about percent to about 15 percent based on interactants charged. Then to this product is added the additional formaldehyde to bring the overall molar ratio to from about 3 to about moles, preferably about 4 to 6 moles, of formaldehyde per mole of alkylsulfonamide. The interaction of the reactants in this second step may be carried out at elevated temperatures, as above described, or at ambient temperatures, i.e., about 20 to 40 C. Whether or not heat is applied, the product will have the free formaldehyde content within the range as previously set forth.

The manner in which the three components of the aforesaid reaction mixtureinteract to form the textile-finishing product of this invention is not known, nor has the chemical structure of the final product been ascertained. Attempts to analyze the product's chemical structure while in aqueous solution have proved fruitless, and when evaporated to dryness, the product appears as a transparent, slightly tacky film. Attempts to analytically determine the chemical structure of this dried solid have also failed. Moreover, elemental analysis of the product to detemiine the sulfur, nitrogen and formaldehyde group content thereof does not permit a postulation of a specific chemical structure which could be assigned to the possible condensation products of the interactants.

APPLICATION OF THE PRODUCT TO CELLULOSIC TEXTILES As aforementioned, the reaction product solution, as synthesized, usually contains from about 30 to about 50 weight percent of dissolved solids (interactants). The fabrictreating solution is prepared by diluting the aforesaid solution to a solids concentration of from about 7 to about weight percent. The pH of the treating solution is usually adjusted to the acid side, before the addition of the curing catalyst, preferably within a pH range of from about 3 to about 5. The pH control is accomplished by adding a small but sufficient amount of free acid to the solution. Suitable free acids include the inorganic acids such as hydrochloric, sulfuric and phosphoric acid and the organic acids such as formic, oxalic, acetic, citric acid, etc. A conventional acidic curing catalyst of accelerator is then added to the solution. Preferred catalysts are certain metallic salts, for example, magnesium chloride, zinc chloride, zinc nitrate, aluminum chloride, zinc fluoborate, magnesium fluoborate, magnesium hydrogen phosphate, and the like. The concentration of the catalyst can range, depending on the particular catalyst chosen, from about 10 percent to about 50 percent, and is generally from about to 30 percent, based on the weight of the dissolved solids in the treating solution. In lieu of the aforementioned metallic salts, other acidic curing catalysts well known in the art may be used, such as a free acid, for example, phosphoric, tartaric or oxalic acid, or an amine salt such as diethanolamine hydrochloride or the hydrochloride of 2-amino-2-methyl-lpropanol. Other conventional additives may be added to the padding bath to impart particular end use characteristics to the fabric, for example, optical brighteners, softeners, hand builders, water and oil repellents, and biocides and biostats.

The creaseproofing agent of this invention is applied to the cellulosic fabric by contacting the fabric with the described solution in the padding bath" employing techniques well known in the art. This operation is usually performed at ambient temperatures, e.g., about 20 C. to about 40 C. The amount of pickup of the finishing agent on the fabric depends to some degree on the type of fabric; however, the amount of add-on of creaseproofing agent can be largely controlled by the concentration of the solution and the extent to which excess solution is squeezed out of the fabric by its subsequent passage through squeeze rolls. Generally, in accordance with this invention, the add-on of creaseproofing agent is on the order of about 2 to about 8 weight percent of solids based on the weight of dry fabric. The lower range of about 2 to 5 percent of solids add-on is regarded as a surprisingly small amount of a finishing agent for imparting good wash-wear properties to cellulosic textiles.

The outstanding stability of the padding bath solution of the product of this invention is another advantage of its use. It has been observed that the solutions are stable after standing for periods of from 3 days to as long as several weeks, without any apparent precipitation of solids. In contrast, some commer- 4 cially available finishing agents will develop a haze or show a precipitate after only a few hours of standing in the padding bath.

Following the above-described application of the agent, the impregnated fabric is subjected to a drying and then curing operation to effect the chemical cross-linking reaction between the finishing agent and the cellulose in the textile which imparts the wrinkle-resistant properties to the fabric. The temperatures required to accomplish these steps vary and are influenced to some degree by the catalyst used and the mutual reactivity of the fiber-reactant-catalyst system. The times required to complete the drying and curing operations are inversely related to the temperatures used. The drying operation is generally carried out at from about 60 C. to about C., preferably about 90 C. to about [05 C. for about 5 to 30 minutes. The curing is effected at from about C. to about 190 C. for from about 2 to 15 minutes. Care must be taken when the higher temperatures are used not to prolong the curing period so as to cause injury to the fabric. The curing is usually carried out at from about C. to about C. for from about 2 to 3 minutes.

The products of this invention are also useful in the production of press-free, crease-retained garments as described in U.S. Pat. No. 2,974,432 to W. K. Wamock and F. G. Hubener. The method therein described involves a postcured (i.e., deferred cure) technique wherein a garment fabric is impregnated with a solution of the textile finishing material, the fabric is partially dried below the curing temperature, the fabric is cut to the garment dimensions and sewed and creased into the shape of the completed gannent, and thereafter the garment is cured at elevated temperatures to impart the pressfree properties thereto.

EXAMPLES The examples of the invention that follow are set forth to illustrate the invention and are not to be interpreted as limitative of the scope thereof.

EXAMPLE 1 Sixty parts by weight (I mole) of urea and 60 parts (2 moles) of formaldehyde (168 parts by weight of a 35.7 percent aqueous solution) are mixed together. Ten percent NaOH solution is added to make the solution alkaline to a pH of about 8.5. Ninety-five parts of methanesulfonamide (1 mole) is dissolved in 200 ml. water and this solution is added with stirring over a period of 30 minutes to the previous solution at about 30 C. The reaction is somewhat exothermic. The total mixture is heated to from 50 to 60 C. and held with stirring at these temperatures for 6 hours during which period percent NaOl-l is added incrementally to maintain the alkaline conditions. The free formaldehyde concentration in the solution of the interactants is about 12 percent, based on dissolved solids.

Two more moles of fon'naldehyde are added to the foregoing parent reaction product. The solution is then refluxed (ca. 100 C.) for 4.5 hours while maintaining an alkaline pH. The free formaldehyde in the product is about percent based on the reactant solids present.

EXAMPLE 2 The procedure of example 1 is repeated except that the additional formaldehyde charged to the "parent reaction product" is 4 moles per mol of methanesulfonamide initially charged. The free formaldehyde content of the aqueous product is about 25 percent based on the reactant solids present.

EXAMPLE 3 One mole of methanesulfonamide, l mole of urea, and 4 moles of formaldehyde are reacted in aqueous solution at 60 C. at a pH of 7.5 to 9 for 6 hours. The aqueous product contains about 40.2 percent of dissolved solids and about 30 percent of free formaldehyde based on these solids.

EXAMPLE 4 The procedure of example 3 is repeated except that the reaction is carried out for 2 hours at about 100 C. The free formaldehyde concentration in the aqueous product is about 25 percent based on dissolved product solids.

' EXAMPLE 5 The procedure of example 1 is repeated except that the source of the formaldehyde is Methyl Formcel" instead of Forrnaline." The final product contains about 27 percent of free formaldehyde.

The above-described solutions of the creaseproofing agent are diluted with water to padding bath concentrations of about 10 to weight percent and MgCl -6H O curing catalyst is added in an amount of from about 20 to 30 weight percent based on the solution solids. Standard 80x80 print cotton fabric swatches are treated in the padding bath with these solutions and squeezed through rolls until there is about a 100 percent wet pickup in weight by the fabric. The swatches are pin framed to constant dimensions and dried for 10 minutes at 200 F. and cured for 3 minutes at 330 F. After curing, the specimens are given an afterwash which consists of washing and rinsing in an automatic washer at l20l25 F. for a 3-5 minutes normal cycle using such quantities of sodium carbonate, sodium perborate, and Nonic 218" (a nonionic detergent) to give solution concentrations of 0.01 0.1 and 0.05 percent, respectively. The specimens are tumble dried in an automatic drier for 30 minutes at a wash and wear setting. The afterwash serves to remove uncombined, water-soluble, excess finishing materials. The cured and afterwashed fabrics, which have an average add-on of about 5 percent of solids, are evaluated according to the following test procedures.

Wash and Wear Appearance Test Method AATCC 88A-1964T, pg. 13-99, 1965 Technical Manual of the American Association of Textile Chemists and Colorists. This test (low-angle-viewing method) is designed to evaluate the retention of original smooth or surface textured appearance of wash and wear fabrics after repeated home launderings. The test specimen is ordinarily given a relative evaluation rating of from 1 to 5 equivalent to its appearance; the higher the evaluation rating, the better the appearance. A rating of less than 4 is considered as unacceptable; a rating of 5 is considered good; extrapolated ratings greater than 5 are regarded as excellent wash-wear characteristics, such evaluations being superior to the best of the rating standards.

Damage by Retained Chlorine An accelerated test to determine the potential damage caused by retained chlorine in the fabric. Test Method AATCC 114-1965T, pg. 8-106 (multiple sample method), 1965 Technical Manual of the American Association of Textile Chemists and Colorists.

Breaking Strength of Fabrics Test Method ASTM Dl682-59T for measuring the breaking load and elongation of textile fabrics.

The results from the foregoing tests and evaluations of fabrics treated with the compositions of examples l-5 are summarized in table 1.

When Dacron polyester-cotton blend fabrics containing from about 20 to 50 percent cotton are treated with the compositions of this invention in the same manner as the fabrics of the foregoing examples, it is found that the wash-wear properties and strength retentions of the blended fabrics are somewhat better than those of the straight cotton. Alkane sulfonamides having two to four carbon atoms, and a mixture of urea and biuret, are substituted for the methanesulfonamide and urea constituents, respectively, without an appreciable decrease in the quality of the product as a creaseproofing agent.

Comparisons of the performance of the composition of this invention are made with textile finishing products (referred to as samples A-E) containing only two of the three critical components; to similar products whose component molar proportions are not within the scope of the invention; and to commercial creaseproofing agents that are widely used in the industry.

SAMPLE A One hundred and twenty grams of a 50 percent solution of the methylol derivative of glyoxal monourein having the for mula HOHzCN NCHQOII HCCH (a commercial creaseproofing product sold under the trademark Permafresh 183"), is diluted to 420 ml. with water and mixed with 180 ml. of a 10 percent (weight/volume) solution of MgCl,-6H,O.

SAMPLE B One hundred and ten grams of a 45 percent solution of a urea-formaldehyde condensation product (a commercial product sold as Permafresh 424") is diluted with water to a volume of 350 ml. and mixed with ml. of a 10 percent solution of MgCl -fl-l O.

SAMPLE C The free formaldehyde concentration of the pad bath solution is about 30 percent based on dissolved product solids.

EXAMPLE D EXAMPLE E This example is the reaction product of methanesulfonamide, urea, and formaldehyde, but the proportions of said reactants are not within the boundaries of those required to give an acceptable product in accordance with this invention.

Sixty parts by weight (lmole) of urea and 60 parts (2 moles) of formaldehyde (168 parts by weight of a 35.7 percent aqueous solution) are mixed together. Ten percent NaOH solution is added to make the solution alkaline to a pH of about 8.5. Ninety-five parts of methanesulfonamide (1 mole) is dissolved in 200 ml. water and this solution is added with; stirring over a period of 30 minutes t o the previous solution at about 30 C. The mixture is stirred at 50 to 60 C. for 6 hours, 10 percent NaOH solution being added incrementally to maintain the alkaline conditions. The free formaldehyde concentration of the product solution is about 12 percent based on dissolved solids. A slight precipitate is noted after 24 hours in the padding bath prepared from a percent solution of this product.

Samples A-E are used to impregnate cotton swatches using the techniques described in the preceding examples. The specimens are similarly dried, cured, and evaluated. The data is summarized in table I. The results show that the wash-wear properties of the fabrics treated in accordance with this invention are significantly better than those of the compared samples.

TABLE I Wash-wear ratings Chlorine retention Treatment after specified number Test retention of Example No. ofhome-type launderings Breaking strength I 5 I0 I 5.] 5.2 5.0 good 2 5.1 5.3 5.3 good 3 5.0 5.2 5.] excellent 4 5.2 5.1 5.2 excellent 5 5.3 5.1 4.9 good Sample No.

A 4.9 4.9 4.9 excellent B 4.3 4.3 4.4 poor C 3.4 3.7 4.0 excellent D 4.7 4.8 4.7 good E 4.0 3.7 3.5 poor Notes: Strength Retention Ratings:

poor: 35% loss in strength fair: 20-35% loss in strength good: 5-2070 loss in strength excellent: 5% loss in strength I claim: 1. A method for creaseproofing cellulosic textile material which comprises treating said material with a composition comprising the product of the interaction in aqueous media at temperatures within the range of about 50 C. to about C. for from about 2 to about 12 hours of 1 mole of methanesulfonamide, from about 0.2 mole to about 2 moles of a urea selected from the group consisting of urea and carbamylurea and mixtures thereof, and from about 3 to about 10 moles of formaldehyde, said product characterized by having a free formaldehyde content of from about 10 percent to about 50 percent weight based on the combined weight of the methanesulfonamide, urea and formaldehyde, and a curing catalyst therefor, drying the impregnated textile material, and thereafter curing said composition on the textile material by the application of heat.

2. A method in accordance with claim 1 wherein the composition comprises the product of the interaction of 1 mole of methanesulfonamide, from about 0.5 to about 1.5 moles of urea, and from about 3 to about 10 moles of formaldehyde.

3. A method in accordance with claim 1 wherein the composition comprises the product of the interaction of 1 mole of methanesulfonamide, essentially 1 mole of urea and from about 4 to about 6 moles of formaldehyde, and the free formaldehyde content of the composition is from about 12 percent to about 40 percent by weight.

4. A method in accordance with claim 1 wherein the curing catalyst is selected from the group consisting of magnesium chloride, zinc chloride, zinc nitrate, aluminum chloride, zinc fluoborate, magnesium fluoborate and magnesium hydrogen phosphate. 

2. A method in accordance with claim 1 wherein the composition comprises the product of the interaction of 1 mole of methanesulfonamide, from about 0.5 to about 1.5 moles of urea, and from about 3 to about 10 moles of formaldehyde.
 3. A method in accordance with claim 1 wherein the composition comprises the product of the interaction of 1 mole of methanesulfonamide, essentially 1 mole of urea and from about 4 to about 6 moles of formaldehyde, and the free formaldehyde content of the composition is from about 12 percent to about 40 percent by weight.
 4. A method in accordance with claim 1 wherein the curing catalyst is selected from the group consisting of magnesium chloride, zinc chloride, zinc nitrate, aluminum chloride, zinc fluoborate, magnesium fluoborate and magnesium hydrogen phosphate. 